Paperboard cushioning cell construction

ABSTRACT

A single-piece blank of paperboard or corrugated board capable of being folded to provide a pair of spaced apart parallel panels. Upon folding, there is realized an end cell cushioning construction connecting at least a pair of adjacent ends of the parallel panels. Also, the blank can be formed so that upon folding, a pair of opposite ends of the parallel panels can be connected by similar end cell cushioning constructions. The cushioning cell construction is suitable for use both in making spacer pads or pallets for use as interior protective devices in shipping containers or for making shipping containers for mailing books or the like.

Unite States Patent Partain et al. 1 May 30, 1972 [54] PAPERBOARD CUSHIONING CELL 3,263,897 8/1966 Giroux ..229/4o CONSTRUCTION 3,116,005 12/1963 Skaggs ..229 40 [72] Inventors: James H. Partain, Norcross, 6a.; Richard H. Johnson, Arlington Heights, 111.

[73] Assignee: Stone Container Corporation, Chicago, Ill. [22] Filed: June 29, 1970 [21] Appl. No.: 50,447

[52] U.S. Cl.. ..229/40, 206/46 FR [51] int. Cl ..B65d 85/00 [58] Field of Search ..206/46 FR; 229/40 [56] References Cited UNITED STATES PATENTS 2,540,065 1/1951 Williamson ..229/40 UX 3,399,821 9/1968 Ringholz ..229/40 3,289,824 12/1966 Boitel 206/46 FR Primary ExaminerEvon C. Blunk Assistant Examiner-W. Scott Carson AttorneySilverman & Cass [57] ABSTRACT A single-piece blank of paperboard or corrugated board capable of being folded to provide a pair of spaced apart parallel panels. Upon folding, there is realized an end cell cushioning construction connecting at least a pair of adjacent ends of the parallel panels. Also, the blank can be formed so that upon folding, a pair of opposite ends of the parallel panels can be connected by similar end cell cushioning constructions. The cushioning cell construction is suitable for use both in making spacer pads or pallets for use as interior protective devices in shipping containers or for making shipping containers for mailing books or the like.

29 Claims, 37 Drawing Figures PATENTEDmmao 1972 3,666,168

sum u or 7 '9 7' TOFA BS PAPERBOARD CUSHIONING CELL CONSTRUCTION BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates generally to paperboard blanks capable of being folded selectively for making spacer pads or pallets and/or shipping containers for mailing books, or the like, and more particularly, relates to improvements in cushioning cell constructions for connecting a pair of spaced apart parallel panels suitable for use in making interior protective devices, such as spacer pads or pallets or in shipping containers for mailing articles, said cushioning cell construction being formed at adjacent ends of the parallel panels merely by folding the blank to orient the panels in spaced apart parallel planes.

2. Description of the Prior Art In U.S. Pati No. 3,055,574 issued Sept. 25, 1962 to Richard H. Johnson, there is disclosed a book mailing folder erected from a single blank of paperboard or corrugated board material. The mailing folder is further characterized by a recessed square or box pleat at a pair of opposite ends thereof providing an internal cushioning construction for preventing sliding movement of the article packaged therein and protecting corners of the article during shipment, such as in the case of shipping books in the folder. The book mailing folder of said U.S. Pat. No. 3,055,574 requires the use of machinery which implements the necessary additional folding operations for achieving the recessed or square-pleated end construction which is formed of three, hingedly connected sections of paperboard.

U.S. Pat. No. 3,227,356 issued Jan. 4, 1966 to S. L. Eifrid teaches a single-blank shipping container for books, for instance, which also employs a recessed end cushioning construction requiring such additional folding steps in order to erect the container. This U.S. Pat. No. 3,227,356 is further characterized by additional slotting of the blank which necessitates additional operations as well.

In U.S. Pat. No. 3,116,005 issued Dec. 31, 1963 to B. T. Skaggs, there is disclosed a shipping container having a recessed cushioning construction at opposite ends of the container similar in concept to the shipping container of U.S. Pat. No. 3,227,356.

U.S. Pat. No. 3,399,821 issued Sept. 3, 1968 to N. A. Ringholz teaches a one-piece blank which is foldable to provide a shipping container for books. When folded, there is achieved a pair of parallel panels connected at opposite ends by a cushioning cell construction which is not recessed in the manner of U.S. Pat. Nos. 3,055,574 and 3,227,356. Pat. No. 3,399,821 teaches a paperboard blank which can be folded to orient a pair of panels in parallel planes thereby achieving the cushioning cell constructions connecting the panels at a pair of opposite ends thereof merely by orienting the panels in said parallel planes.

In U.S. Pat. No. 3,221,973 issued Dec. 7, 1965 to T. S. Kalbrener, there is disclosed a spacer pad or pallet construction which may be formed likewise from a single blank of corrugated paperboard. A cushioning cell construction at adjacent ends of the parallel panels is realized upon folding of the blank to arrange the panels in parallel planes. However, in the Kalbrener U.S. Pat. No. 3,221,973, the spacer pad or pallet taught is limited in concept to an internal protective device for shipping containers and no consideration is given utilizing this end cell cushioning construction in shipping containers for mailing books or other articles.

SUMMARY OF THE INVENTION The invention contemplates a single-piece blank of paperboard or corrugated board which can be selectively folded to make a shipping container for mailing books or other articles or for making spacer pads or pallets for use as internal protective devices in shipping containers. In each instance, the blank is capable of being folded to orient a pair of panels in spaced parallel planes connected by end cell cushioning constructions which are fonned automatically upon folding of the blank to orient the panels in spaced parallel planes. The end cell cushioning construction is provided by a slotted end-wall arrangement connecting the parallel panels to provide a unique configuration of interwoven strips of paperboard which will support the panels in said parallel spaced relationship and protect the comers of the resulting box-like configuration. The space between the panels forms a shipping cavity for books, for instance, the corners of which are internally protected by means of the end cell cushioning construction without damaging the book or other packaged article during shipment of the container. Yet, the parallel panels are desirably rigidified in their parallel orientation by the connecting end cell cushioning construction so that the resulting structure can be used advantageously as an internal protective device, such as a spacer pad or pallet.

A paperboard blank from which an end cell cushioning structure can be formed includes a web of paperboard having at least one pair of inverted, contiguous triangularly shaped panels extending across an intermediate portion of the web. The legs of the triangularly shaped panels are creased and are askew of the axis about which the blank is folded. The base of each triangular panel is formed by a cut edge. In general, a plurality of apex-to-base aligned pairs of triangles extend across an intermediate portion of the web. To erect the end cell cushioning structure, one side of the web is folded about the folding axis, and out of the plane of the web. In the preferred embodiment, the sides of the web on either side of the cushioning cell are generally folded into an overlying parallel relation. However, this is not intended to be limiting since structures having non-parallel surfaces can be envisioned. The cushioning cell is formed by rotating one side of the web about the folding axis so that the side and the triangularly shaped panels no longer lie in the web plane. When this is done, the portion of the triangularly shaped panels which remains in the web plane is the non-common leg of the triangle which was previously in that plane. As the side is folded about the folding axis, there is a pivoting motion about the non-common legs; the bases or cut edges of the triangular panels project inwardly and provide the points against which an article disposed within a container rests. Thus, the triangularly shaped panels appear to slope outwardly from the panel in which the non-common leg lies.

This cushioning cell structure can be incorporated into opposed sides of book mailers so that opposite sides of the book will rest against the bases of the trangles and be cushioned thereby. Furthermore, spacer pads or pallets can be formed from a blank having a pair of cushion-cell arrangements spaced apart so that by proper folding, a box-like configuration having the cushion cells opposite one another can be fabricated. This spacer pad can then be inserted into a larger container as an internal protective device.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view of a blank of paperboard for erecting a shipping folder for which, when folded, will form the cushion cell for books or the like in accordance with this invention, the book article having been omitted for purposes of clarity.

FIG. 2 is a perspective view showing the blank of FIG. 1 in one stage of erection of the shipping folder.

FIG. 3 is a perspective view showing the blank of FIG. 2 in another stage of erection preparatory for completion of the folder, but inverted from normal orientation through a packaging machine.

FIG. 4 is a perspective view showing the blank of FIG. 3 further folded for completing the folder.

FIG. 5 is a perspective view showing the shipping folder of FIG. 4 completely erected.

FIG. 6 is a fragmentary sectional view taken along line 66 of FIG. 5 but, additionally, showing the ends of a book cushioned against a cushioning cell construction formed when the folder is erected.

FIG. 6A is a plan view of a modified blank of paperboard albeit, similar to the blank of FIG. 1 in basic respects.

FIG. 7 is a plan view of a modified form of the paperboard blank embodying the invention.

FIG. 8 is a plan view of another modified form of paperboard blank embodying the cushioning cell invention utilized in a shipping folder.

FIG. 9 is a plan view of another modified form of paperboard blank embodying the cushioning cell invention utilized in a shipping folder.

FIG. 10 is a plan view of another modified form of paperboard blank with the cushioning cell invention utilized in a shipping folder.

FIG. I I is a plan view of a representative paperboard blank embodying the invention for erecting a spacer pad having a pair of cushioning cell constructions at opposed ends.

FIG. 12 is a perspective view of the blank of FIG. 11 in a partially erected spacer pad condition.

FIG. 13 is a perspective view of the blank of FIG. 12 completely erected.

FIG. 14 is a plan view of a fragmentary paperboard blank of the invention illustrating a cushioning cell structure formed from scalene-shaped triangular panels having closely spaced altitudes.

FIG. I5 is a perspective view of the blank of FIG. 14 in erected condition.

FIG. 16 is a plan view of a fragmentary blank of the invention wherein the cushioning cells are formed from a plurality of scalene-shaped triangular panels, which are larger than those of FIG. 15.

FIG. 17 is a plan view of a fragmentary blank of the invention in which the cushioning cell is formed from equilaterally shaped triangular panels.

FIG. 18 is a plan view of a fragmentary blank of the invention for forming a cushioning cell which is the mirror image of FIG. 17.

FIG. 19 is a perspective'view of the cushioning cell structure formed by erecting the blank of FIG. 18.

FIG. 20 is a plan view of a fragmentary blank for realizing a cushioning cell construction wherein the slits forming the bases of the triangular panels form an acute angle with respect to the folding axis.

FIG. 21 is a perspective view of the cushioning cell structure formed by erecting the blank of FIG. 20.

FIG. 22 is a plan view of a fragmentary blank for forming a cushioning cell structure wherein the bases of the triangular panels are disposed at an obtuse angle with respect to the folding axis.

FIG. 23 is a perspective view of the cell structure realized by erecting the blank of FIG. 22.

FIG. 24 is a perspective view of the erected blank of FIG. 23 and looking in a direction into the structure to show engagement between the edges of the bases of the panels.

FIG. 25 is a plan view of a fragmentary blank for forming a cushioning cell structure wherein one row of triangularly shaped panels is displaced downwardly with respect to the other row.

FIG. 26 is a perspective view showing the erected cell structure formed by folding the blank of FIG. 25.

FIG. 27 is a plan view of a fragmentary blank for forming a cushioning cell structure having interlocking cushioning cells wherein one row of triangularly shaped panels is displaced downwardly so as to form a non-linear slit and a slot is provided in the base of the displaced panel adjacent the apex of the abutting panel.

FIG. 28 is a fragmentary sectional view taken through a cushioning cell erected from the blank of FIG. 27 and showing the interlocking of a base edge and slot.

FIG. 29 is a perspective view of an erected interlocking cushioning cell formed from the blank of FIG. 27.

FIG. 30 is a plan view of another fragmentary blank for forming a cushioning cell structure wherein a row of triangular panels has been displaced downwardly so as to form arrowhead-shaped panels in the contiguous row.

erected cushioning cell structure formed from the blank of I FIG.32.

FIG. 34 is a plan view of another fragmentary blank wherein the slits forming the bases of the triangular are not straight parallel lines.

FIG. 35 is a perspective view of the exterior of a partially erected structure formed from the blank of FIG. 34.

FIG. 36 is a plan view of another fragmentary blank wherein the apices of the triangular panels are truncated.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings, FIGS. 1-6 illustrate a blank 10 and the manner of progressive folding thereof to form a shipping container or a book mailer in accordance with this invention. The blank I0 can be cut from a single web of paperboard or corrugated board in a continuous mass production system, as is a common practice in this field. The slitting and scoring which must be done preferably is performed in the same operation but may be done subsequently. The slits and creases or fold lines enable the various panels and flaps for the book mailer to be realized when the blank is folded to erect the same, the various panels and flaps being hingedly connected along the fold lines or creases. These folds or creases will be referred to generally but not designated by reference numerals, except where deemed necessary for purposes of clarification or amplification. In the following description the term cushion cell arrangement will be used to describe the unerected cushion cells.

The blank 10 has a first rectangular panel 12 and second rectangular panel 14 of similar size and shape which are interconnected along a pair of creases by a side wall panel I6. Wall panels 18 and 20 are hingedly connected to the side edges of the panel 12 along another pair of creases. A pair of flaps 22 and 24 are connected to the wall panels 18 and 20. Another side wall panel 26 is connected to the panel 12 along its front edge. To the outer edge of the panel 26 is hingedly connected a front flap 28.

The cushioning cell arrangement designated generally 30 and 32 is shown in FIG. 1, prior to folding of the blank. When folded, the cell arrangement 30 forms a row or array of cushioning cells for protecting the article, such as a book, which contacts the cells. It will be appreciated that each array of cushion cells generally forms a side wall of the container or book mailer.

In order to form the cells, a cell flap or panel 34 or 36 is provided which is hingedly connected to the outer sides of the cell arrangements 30 and 32. The flaps and cell arrangements are folded about an axis which is parallel to the cell arrangements and the side wall of the mailer. Each cell arrangement includes a plurality of pairs 38 of alternately inverted contiguous triangularly shaped panels 40 and 42. The sides or legs of the panels are formed by three creases which are askcw the folding axis. The bases of the triangles are free edges and are formed by a slit. The apex of one triangle and base of the other triangle in the pair generally lie along the slit or can be characterized as being flush with one another. The non-common legs are generally in parallel relation to one another with the panels being hingedly connected along the common leg. The altitudes of the panels in each pair are generally parallel to one another and parallel to the folding axis. Depending upon the shape of the triangularly shaped panels, that is, if the triangles are scalene, isosceles, or equilateral, the cell flap 34 when folded may or may not be laterally displaced with respect to the panel 14. To control the displacement so that, when the mailer is erected, the cell flap is aligned with respect to the top panel, the end portions of the cell arrangements 30 and 32 may be cut transverse to the folding axis.

To erect the mailer, the blank is fed through an automatic packaging machine with the book placed on the flat blank prior to folding commencing. Normally, the blank 10 would be moved through the machine in direction of the arrow in FIG. 2. The cell flaps 34 and 36 are folded upwardly and inwardly toward one another and into parallel relation with the top panel 14, as is seen in FIG. 2. The folding of the panel 34 causes the panels 40 and 42 to appear to project outwardly. The base of the panel 40 appears to extend outwardly from the point at which it contacts the top panel 14 to the point at which it contacts the cell flap 34. However, in fact both innermost points are displaced the same distance inwardly with the maximum outward displacement being at the point where the bases join either the top panel 14 or the cell flap 34. After the cushion cells are formed, the entire top panel 14 with the cushion cells is folded along the back panel creases so that the cell flaps 34 and 36 contact the bottom panel 12. In this construction, the back panel is at right angles with the top and bottom panels 12 and 14 as seen in FIG. 3. The top surfaces of the cell flaps can be adhesively secured to the bottom panel so as to form an open ended sleeve. Thereafter, the front panel 26 and flap 28 can be folded and secured in place to enclose the book for shipping.

However, the cushion cells have openings adjacent the slit edge of the bases of the triangularly shaped panels which permits entry of foreign matter and possible damage to package contents. To completely protect the contents, side panels 18 and 20 with side flaps 22 and 24, respectively, have been provided. These side panels and flaps are folded as seen in FIG. 4 to completely close the cells and the mailer. Normally, the side panels and flaps would be secured to the top panel 14 by adhesive or bonding tapes. The previous two steps can be ap preciated from FIGS. 4 and 5.

The ends or edges of the book, as distinguished from the binding or spine, contact the cushion cells along the slit edge base of the triangular panels at the points where the panels are most inwardly displaced; that displacement is at the point of contact of the bases with the top 14 and cell flap 34. From FIG. 6, it is apparent also that the triangular-shaped panels form an oblique angle with respect to its adjacent top or cell flap. In FIG. 6A, a modified blank is shown in which the slit edges forming the base of the triangular panels are angled or canted as compared to the blank of FIG. 1.

Numerous variations in the arrangements, size and shape of the various panels can be made. FIGS. 7-10 depict four such alternate embodiments, but it is not intended that the scope of the invention be limited thereby. In the discussion which follows, those illustrated parts which are identical or similar will bear similar names and reference numerals.

Referring now to FIG. 7, there is shown a blank for a book mailer wherein the panel 14, cell arrangements and 32 and cell flaps 34 and 36 are similar to those shown in FIG. 1. However, the panel which corresponds to panel 12 is split into two ponions 12A and 128 with the side panels and flaps being similarly split. The top panels 12A and 12B are hingedly interconnected to the panel 14 at the back panel 16 and front panel 26. When erected, the cell flaps 36 and 34 are folded upwardly and toward one another into a parallel relation with the panel 14, thereby erecting the cushion cells. The panels 12A and 12B are brought into an abutting relationship overlying the panel 14. The side flaps and side panels 18, 22, 20 and 24 are then folded downwardly and around the cells to complete the mailer. The mailer is closed by adhesively securing the flaps 22A, 22B, 24A and 24B to the underside of panel 14 and by adhesively taping the joint formed by the abutment of panels 12A and 12B. Of course, in the construction of such a mailer, the book may be placed on panel 14 and the mailer erected thereabout; in the alternative, one-half of the mailer can be erected leaving one side open for the insertion of the book, after which, the mailer can be sealed by folding over the remaining panels and flaps.

The blank disclosed in FIG. 8 is similar to that of FIG. 1 which with the exception that it is not provided with side panels or flaps or a front flap. It will be noted that the cell flaps 34 and 36 are creased along lines 44 and 46. When the cushion cell arrangements are erected, the flaps 34 and 36, as before, are folded upwardly and toward one another and into a generally parallel relation with the panel 14. However, since no side panels or flaps are provided, if the cell flaps were left in that configuration, entry of foreign material into the mailer would not be prevented. To prevent such entry, the cell flaps 34 and 36 themselves are further folded at right angles along the creases 44 and 46 so that the edges of the flap contact and are in perpendicular relation to the panel 14. In this configuration, the cushion cells are exposed rather than hidden and the book edges rest against the cell flaps 34 and 36. To complete erection of the mailer, the panels 16, 12 and 26 are folded in a manner previously described for the mailer blank of FIG. 1. The mailer can then be sealed by taping the exposed edges. The front panel 26 may be left open so that a sleeve will be formed into which a book may be inserted. Thereafter, the sleeve can be closed by sealing the front panel. Of course, the book can be placed on panel 14 and the mailer erected thereabout.

FIG. 9 depicts an embodiment which incorporates features of FIGS. 7 and 8. The panel 12 in FIG. 9 is split into two portions 12A and 12B as in FIG. 7, but the panels 12A and 12B are not provided with side panels or flaps as in FIG. 8. As in FIG. 8, to prevent entry of foreign material, the cell flaps 34 and 36 are creased along 44 and 46 so that when the cushion cell arrangements 30 and 32 are erected, the interior of the mailer is sealed by the flaps 34 and 36 being adjacent the cushion cells and in perpendicular relation to the panel 14. Assembly of the mailer then is completed by folding the panels 12A and 12B and 16 and 26 as described for the mailer of FIG. 7 and taping.

In the embodiment shown in FIG. 10, the cushion cell arrangements 30 and 32 are joined to panels 12 and 14 in such a manner that when erected, the cushion cells form wall 16A and 26A which correspond to the walls 16 and 26 shown in FIG. 1. From this it is seen that the cushion cells can form the front and back walls or side walls of the mailer and be interconnected with the top and bottom panel; they need not be limited to being connected to one panel and utilizing a pair of cell flaps.

To erect the mailer, the cell flap 34 is folded as previously described to erect the cushion cell arrangement 30. The panel 12 is then folded over into a superposed relation with panel 14, thereby erecting the cushion cell arrangement 32. Thus, the panel 12 overlies the flap 34. Next, the side panels 18C and 18D and 20C and 20D are folded inwardly to form the sides of the mailer. The mailer then may be sealed by taping or other conventional means. As with the previous mailers, the book may be set on panel 14 and the mailer erected thereabout, or the blank may be erected to form a sleeve with one side open. For example, the mailer could be completely erected with panels 20C and 20D not folded. The book could he slipped into the mailer through the opening in side 20 and the mailer sealed by closing the panels 20C and 20D.

The above discussion has been related to variations in the panel and flap size, construction and arrangement with little, if any, variation in the cushion cell arrangements. Although the disclosure has been directed to a book mailer, it is not intended that the invention be so limited. From the disclosure as hereinafter presented, it will be apparent that: (l) variations can be made in the cushion cell arrangement and (2) in the structures formed so that said cell concept can be applied to internal protective devices, such as, spacer pads for shipping containers as well as book mailers. Also, sizes of panels can be varied for specific functions or usages intended to be achieved.

The representative cell construction derived from a blank is depicted in FIGS. 11, 12 and 13. The blank 100 has a panel 102 to which cushion cell arrangements 104 and 106 are hingedly connected. Cell flaps 108 and 110 are hingedly connected to the outer non-common legs of the cell arrangements 104 and 106 respectively. The size, shape and positioning of the triangular-shaped panels in the cell arrangements 104 and 106 are identical to those in the cell arrangements 30 and 32. Thus, the cushion cells formed will be substantially identical. The blank is erected by folding the cell flaps 108 and 110 upwardly and toward one another; to the partially erected condition seen in FIG. 12. FIG. 13 shows the completely erected cushion cells with the cell flaps 108 and 110 in parallel relation to the panel 102.

Embodiments varying in size, shape and location of the triangular panels in the cushioning cells arrangement are illustrated in FIGS. 14-31. To best depict these variations, sample blanks having the cushion end cells across an intermediate portion thereof with cell flaps on either side of the end cells are shown. It will be appreciated that these can be used in combination with the mailers and spacer pads, as previously described. The triangular panels should generally conform to the shape of equilateral, isocelese, or scalene triangles for best results, although, if the triangles are right angle or obtuse, they may form the desired cushion cell under proper dimensional relationships.

The cushion cell arrangement must include at least one pair of contiguous inverted triangular-shaped panels. However, in practice, there is normally a plurality of pairs aligned in a front-to-back or apex to-base relation. These pairs extend across an intermediate portion of the web which is to befolded. The width of each cushion cell or, in other words, the number of cells per unit length, is related to the distance between the points formed by the intersection of the base and a non-common leg, for two adjacent aligned triangularly shaped panels. In most cases where the base is normal to the fold axis, that distance will be equal to the altitude of the triangular panel. It is apparent that as that distance is decreased, a number of cells per unit length is increased. That distance will hereinafter be designated W and is so indicated on the drawings. The depth of a cell is proportional to the shortest distance between the point at which the apex of a triangle abuts the base of the contiguous aligned panel and the line along which the width of the cell was determined. This distance is indicated as D in the accompanying drawings and it will be seen that in the case of an isosolese or equilateral triangle, D is equivalent to one-half the base of the triangle. It will be appreciated that as D is increased, the depth of the cell is increased. When the cell flaps are folded into an overlying parallel relation, the distance between the parallel panels ie., the cell flap and top panel, is related to the distance between the two parallel lines each of which connect the apexes of the triangular panels arranged in front-to-back relation. This distance is indicated as H on the accompanying drawings and is a function of D and W. As H approaches 0, the height of the cells approaches so that when H is equivalent to 0, the two cell flaps fold flat against one another and in effect, there are no cells. Thus, by controlling W, D and H, the size of the cell is controlled.

In comparing FIGS. 14 and 16, it is seen that W, D and H of FIG. 16 is smaller than W, D and H of FIG. 14. Thus, there will be more cells per unit length in FIG. 16 than in FIG. 14. The depth of the cells in FIG. 16 will be less than the cells in FIG. 14, and the height will be less in 16 than in 14. In FIGS. 17 and 18 the width (W), depth (D) and height (H) are identical but the orientation of the rows of apex-to-base triangles has been reversed. The reversal of these rows does not affect the size of the cells, but merely orients them in a mirror image to those fabricated from FIG. 17. FIG. 19 depicts the erected cushion cells formed from the arrangement of FIG. 18.

If the base of the triangular panels is not normal to the two parallel lines connecting the apexes of the triangles, the distance between the base edges of adjacent cushion cells can be controlled so as to provide for contact. This spacing or contacting can be controlled by controlling the angle at which the base intersects the parallel lines connecting the apexes of aligned adjoining triangular panels as measured within the panel and on the side toward the non-common leg. That angle is denoted as alpha (or) in FIGS. 20 and 22. When alpha is less than about the cell edges will be separated. However, when alpha is greater than 90, the edges will be in contact. Thus, the cells erected from the blank of FIG. 20 shown in FIG. 21 will have the edges separated. However, the cells formed from the blank of FIG. 22, as shown in FIGS. 23 and 24, will have their edges in contact. FIG. 24 best depicts this contact.

In the foregoing discussions, the non-common parallel legs are of equal length. However, if it is desired to assure contact or spacing, this can be accomplished by making the non-common legs unequal in length. FIG. 25 depicts a cell arrangement wherein the non-common leg of each panel in one row of triangular panels is somewhat longer than the non-common leg of the other row. Thus, the panel is not truly triangular-shaped but has assumed a somewhat arrow-head like shape. When such a blank is folded to form the cushion cells, as in FIG. 26, the base edges are separated. F I68. 30 and 31 depict a similar arrangement. On the other hand, where one leg is made shorter than the other, as in FIG. 27, contact is assured between the cell or base edges. The panels are not exactly triangular but have an outwardly projecting base portion. Since the cell edges are in contact, it is possible to cause them to interlock by providing a slot in the base of one panel at the point where it abuts apex of an adjoining triangle. FIG. 29 depicts an erected cushion panel having interlocking edges and FIG. 28 is a sectional view thereof.

FIGS. 32 and 34 show blank structures in which the slit edges 112 forming the triangle bases are segmented, as indicated at 114, so that the bases of the triangles are not formed from straight parallel lines. Although modified to somewhat quadrilateral configuration, a generally triangular panel is still discernible.

Referring to FIG. 36, another embodiment is illustrated in which the panels 40 and 42 are truncated at their apices, as shown at T. The base lines opposite the truncated parts are straight lines, however, thereby giving rise to a parallelogram configuration for panels 40 and 42.

The reinforcing panels herein can be used in combination with the cell arrangements previously shown to form shipping containers as spacer pads.

The blanks of this invention can be shipped to the user in a flat collapsed position and partially or completely erected as desired. Thus, the user can store and use the blanks, as desired.

What it is desired to secure by Letters Patent of the United States is:

1. A protective structure which is formed from a web of foldable material when folded about a folding axis and which includes at least two cushion cells, said structure comprising:

a. a panel and a cell flap hingedly interconnected to said cushion cells on opposite sides thereof with at least one slit extending between said panel and said cell flap and separating said cushion cells,

b. each cushion cell having a pair of contiguous inverted generally triangularly shaped panels hingedly interconnected along a common leg formed by a crease, said panel and cell flap being hingedly interconnected to each cushion cell on opposite sides thereof each along one of the two non-common legs formed by creases,

d. said non-common legs both being skew to the folding axis,

f. an obtuse angle being formed between the plane of each of said triangularly shaped panels and the plane of said panel connected thereto or the plane of said cell flap connected thereto,

g. the base portion of each triangularly shaped panel being defined by a free edge of said web of foldable material, and

h. each pair of said triangularly shaped panels being situated between two free edges in said web with the apex of one of said triangularly shaped panels in one pair of said triangularly shaped panels being at one of the free edges defining said slit and abutting the opposing free edge of said slit which opposing free edge forms the base of another triangularly shaped panel in the adjacent pair of triangularly shaped panels.

2. The structure as claimed in claim 1 being a flat rectangularly shaped book mailer and wherein said structure includes two arrays of said cushion cells, said panel constituting a first panel which forms the top panel of the mailer and being hingedly interconnected along opposite sides thereof to said array of cushion cells which form side walls of said structure, a back panel which is interconnected with said first panel and which is disposed at right angles thereto, a second or bottom panel parallel to and aligned with said first panel and hingedly connected to said back panel, and a front panel hingedly interconnected to said bottom panel and being disposed across the open end of said mailer to close said mailer.

3. The structure as claimed in claim 2 wherein a pair of side panels and side flaps are hingedly connected to the sides of the second panel, the side panels being folded over the outside of the cells with the side flaps being adhered to the top panel, and there being a front flap hingedly connected to the front panel and adhered to the top panel thereby forming an enclosed book mailer.

4. The structure as claimed in claim 1 being a flat rectangularly-shaped book mailer and wherein said structure includes two arrays of said cushion cells, said panel constituting a first panel which forms the top panel of said book mailer and being hingedly interconnected along opposite sides thereof to said arrays of cushion cells which form side walls of said structure, a back panel and a front panel which are hingedly connected with said first panel on the remaining sides thereof and which are disposed in an upright position, and a split second panel parallel to and aligned with said first panel, one portion of said split panel being connected with said front panel and the other portion being connected to said back panel.

5. The structure as claimed in claim 4 wherein the cell flap is creased and folded so that it is adjacent the cells and disposed normal to the first and second panels.

6. The structure as claimed in claim 4 including split side panels which have split side flaps and which are hingedly connected to said portions of said split second panel, said split side panels being disposed over the outside of said cushion cells and said side flaps being adhered to said first panel.

7. The structure as claimed in claim 1 being a flat rectangularly shaped book mailer and wherein said structure includes two arrays of said cushion cells, said panel constituting a first panel which forms the bottom panel of said mailer and being hingedly connected along opposite sides thereof to said arrays of cushion cells, said arrays of cushion cells forming the sides of said mailer, a second panel which forms the top panel of said mailer being aligned with and in parallel relation to said first panel and being hingedly connected to one of said arrays of cushion cells, said cell flap being hingedly connected to the other of said arrays of cushion cells, said flap being parallel to and adjacent said second panel, and a pair of upstanding panels forming the front and back panels of said mailer and being hingedly connected to said first panel.

8. The structure as claimed in claim 1 wherein said cushion cells are in contact with each other adjacent the bases of said triangularly shaped panels thereof.

9, The structure as claimed in claim 1 wherein a space is provided between the bases of said triangularly shaped panels of said cushion cells.

10. The structure as claimed in claim 1 wherein said cushion cells are aligned so as to form said triangularly shaped panels into two rows, the base of each triangularly shaped panel in one row projecting rearwardly with respect to said panels in said one row, said projecting portion of each base having a notch formed therein, said notch interlocking with the base of an adjacent panel in the other row so as to rigidify said cushion cells.

1 l. A packaging structure which includes a cushion end cell arrangement and which is formed from a single blank of foldable material by folding said blank about a folding axis, said structure comprising: a web of material having at least two cushion end cells extending from side-to-side across an intermediate portion of said web and being separated by at least one slit in said web, each cushion end cell including at least one pair of inverted generally triangularly shaped panels which are hingedly interconnected along a common leg and which are situated between two free edges in said web, each of said triangularly shaped panels having a second or non-common leg and a base, said base of each panel being defined by a free edge of said web of material, said legs being defined by three creases in said intermediate portion of said web of material, said creases being skew to said folding axis when said web of material is folded to form said cushion end cell, said two non-common legs being parallel to one another before said web of material is folded to form said packaging structure, and the apex of one of said triangularly shaped panels in one pair of said triangularly shaped panels being at one of the free edges defining said slit and abutting the opposing free edge of said slit which opposing free edge forms the base of another triangularly shaped panel in the adjacent pair of triangularly shaped panels.

12. The packaging structure as claimed in claim 11 wherein said non-common parallel legs are of unequal length.

13. The packaging structure as claimed in claim 11 in which at least one of said free edges is segmented into non-collinear edge segments.

14. The packaging structure as claimed in claim 11 being a book mailer and wherein said web of material includes at least two additional cushion end cells in another portion of said web, a first panel extending between and hingedly interconnected along opposite edges thereof to said cushion end cells and defining the top panel of said mailer, a pair of cell flaps each hingedly interconnected with the outer sides of said cushion end cells, a side panel hingedly interconnected to one side of said first panel, and a second panel interconnected along one side thereof to said side panel and defining the bottom panel of said mailer.

15. The packaging structure as claimed in claim 14 including a pair of edge panels hingedly interconnected with opposite edges of said second panel, a pair of side flaps hingedly interconnected with said edge panels, a front panel hingedly interconnected to said second panel along the other side thereof, and a front flap hingedly interconnected to said front panel.

16. The packaging structure as claimed in claim 14 including a front panel hingedly connected to said first panel, said second panel being split with one portion thereof hingedly connected to said front panel and another portion thereof hingedly connected to said side panel.

17. The packaging structure as claimed in claim 16 including split edge panels and flaps which are hingedly connected to opposite edges of said two portions of said second panel.

18. A blank of foldable material for forming a packaging structure having a plurality of cushion end cells, said blank including at least two panel portions, and at least one foldable web portion which interconnects said two panel portions, said web portion having a plurality of spaced slits therein extending between said panel portions thereby dividing said web portion into a plurality of web sections and forming a plurality of free edges in said web portion, each of said web sections having three creases therein which extend between two free edges in said web portion and which form a Z in said web section such that two inverted triangularly shaped panels are defined between said creases and said two free edges, each triangularly shaped panel having a base defined by one of said free edges and two legs defined by two of said creases, the crease defining the connecting line of said Z also defining one leg which is common to both of said triangularly shaped panels and which hingedly interconnects said triangularly shaped panels, and the creases defining the end lines of said Z also defining respective non-common legs of said triangularly shaped panels, said non-common legs being parallel to one another, and so that when said web sections are folded along said creases, a cushion end cell is formed in each of said web sections by said triangularly shaped panels therein with each triangularly shaped panel lying a plane which intersects the plane of the other triangularly shaped panel and also the respective planes of said panel portions, and with each web section having a pair of said triangularly shaped panels therein situated between two of said free edges in said web portion such that the apex of one of said triangularly shaped panels in one web section is adjacent the base of another triangularly shaped panel in the adjacent web section.

19. The blank as claimed in claim 18 in which at least one of said free edges is segmented into non-collinear edge segments.

20. The blank as claimed in claim 18 wherein said non-comrnon parallel legs are of unequal length.

21. The blank as claimed in claim 20 wherein the bases of said triangularly shaped panels in one row of panels project rearwardly with respect to the apexes of said panels, and a slot is provided at said projection and adjacent the apex of the adjacent triangularly shaped panel in said one row of panels, so that, when said blank is folded, each of said slots in one of said bases interlocks with the base of one of said panels in the adjoining row of triangularly shaped panels.

22. The blank as claimed in claim 18 wherein a line passing through the apexes of said panels in one of said rows of panels is parallel to a line passing through the apexes of said panels in the adjoining row of said panels, each of said lines intersecting the base of each of said panels in the respective row of panels at an angle (alpha) measured within the panel and on the side toward the non-common leg of said panel.

23. The blank as claimed in claim 22 wherein the angle (alpha) is less than about 90 so that said free edges are separated.

24. The blank as claimed in claim 22 wherein the angle (alpha) is greater than about 90 so that adjacent cells are in contact.

25. A packaging structure which includes at least one cushion end cell and which is formed from a single blank of foldable material by folding said blank about a folding axis, said structure comprising: a web of material having said cushion end cell extending from side-to-side across an intermediate portion of said web and between two free edges in said web, said cushion and cell including at least one pair of inverted generally triangularly shaped panels which are hingedly interconnected along a common leg, each of said triangularly shaped panels having a second or non-common leg and a base, said base of each panel being defined by a free edge of said web of material, said legs being defined by three creases in said intermediate portion of said web of material, said creases being skew to said folding axis when said web of material is folded to form said cushion end cell, and said two non-common legs being of unequal length and being parallel to one another before said web of material is folded to form said packaging structure.

26. The packaging structure as claimed in claim 25 in which at least one of said free edges is segmented into non-collinear edge segments.

27. A blank of foldable material for forming a packaging structure having at least one cushion end cell, said blank including at least two panel portions, and at least one foldable web portion which interconnects said two panel portions, said web portion have three creases therein which extend between two free edges in said web portion and which form a Z in said web portion such that two inverted triangularly shaped panels are defined between said creases and said two free edges, each triangularly shaped panel having a base defined by one of said free edges and two legs defined by two of said creases, the crease defining the connecting line of said 2 also defining one leg which is common to both of said triangularly shaped panels and which hingedly interconnects said triangularly shaped panels, and the creases defining the end lines of said 2 also defining respective non-common legs of said triangularly shaped panels, said non-common legs being parallel to one another and being of unequal length, and so that when said web portion is folded along said creases, a cushion end cell is formed in said web portion by said triangularly shaped panels with each triangularly shaped panel lying in a plane which intersects the plane of the other panel and also the respective planes of said panel portions.

28. The blank as claimed in claim 27 wherein at least one of said free edges is segmented into non-collinear edge segments.

29. A blank of foldable material for forming a packaging structure having at least two cushion end cells, said blank including at least one foldable web portion which interconnects said two panel portions, said web portion having at least one slit therein extending between said panel portions thereby dividing said web portion into at least two web sections and forming a plurality of free edges in said web portion, each of said web sections having three creases therein which extend between two free edges in said web portion and which form a Z in each of said web sections such that two inverted triangularly shaped panels are defined between said creases and said two free edges, each triangularly shaped panel having a base defined by one of said free edges and two legs defined by two of said creases, the crease defining the connecting line of said Z also definingone leg which is common to both of said triangularly shaped panels and which hingedly interconnects said triangularly shaped panels, and the creases defining the end lines of said Z also defining respective non-common legs of said triangularly shaped panels, said non-common legs being parallel to one antoher, and so that when said web sections are folded along said creases, a cushion end cell is formed in each of said web sections by said triangularly shaped panels therein with each triangularly shaped panel lying in a plane which intersects the plane of the other triangularly shaped panel and also the respective planes of said panel portions, and with each web section having a pair of said triangularly shaped panels situated therein between two of said free edges in said web portion such that the apex of one of said triangularly shaped panels in one of said web sections is at one of the free edges defining said slit and abutting the opposing free edge of said slit which opposing free edge forms the base of another triangularly shaped panel in the adjacent web section. 

1. A protective structure which is formed from a web of foldable material when folded about a folding axis and which includes at least two cushion cells, said structure comprising: a. a panel and a cell flap hingedly interconnected to said cushion cells on opposite sides thereof with at least one slit extending between said panel and said cell flap and separating said cushion cells, b. each cushion cell having a pair of contiguous inverted generally triangularly shaped panels hingedly interconnected along a common leg formed by a crease, said panel and cell flap being hingedly interconnected to each cushion cell on opposite sides thereof each along one of the two non-common legs formed by creases, d. said non-common legs both being skew to the folding axis, f. an obtuse angle being formed between the plane of each of said triangularly shaped panels and the plane of said panel connected thereto or the plane of said cell flap connected thereto, g. the base portion of each triangularly shaped panel being defined by a free edge of said web of foldable material, and h. each pair of said triangularly shaped panels being situated between two free edges in said web with the apex of one of said triangularly shaped panels in one pair of said triangularly shaped panels being at one of the free edges defining said slit and abutting the opposing free edge of said slit which opposing free edge forms the base of another triangularly shaped panel in the adjacent pair of triangularly shaped panels.
 2. The structure as claimed in claim 1 being a flat rectangularly shaped book mailer and wherein said structure includes two arrays of said cushion cells, said panel constituting a first panel which forms the top panel of the mailer and being hingedly interconnected along opposite sides thereof to said array of cushion cells which form side walls of said structure, a back panel which is interconnected with said first panel and which is disposed at right angles thereto, a second or bottom panel parallel to and aligned with said first panel and hingedly connected to said back panel, and a front panel hingedly interconnected to said bottom panel and being disposed across the open end of said mailer to close said mailer.
 3. The structure as claimed in claim 2 wherein a pair of side panels and side flaps are hingedly connected to the sides of the second panel, the side panels being folded over the outside of the cells with the side flaps being adhered to the top panel, and there being a front flap hingedly connected to the front panel and adhered to the top panel thereby forming an enclosed book mailer.
 4. The structure as claimeD in claim 1 being a flat rectangularly-shaped book mailer and wherein said structure includes two arrays of said cushion cells, said panel constituting a first panel which forms the top panel of said book mailer and being hingedly interconnected along opposite sides thereof to said arrays of cushion cells which form side walls of said structure, a back panel and a front panel which are hingedly connected with said first panel on the remaining sides thereof and which are disposed in an upright position, and a split second panel parallel to and aligned with said first panel, one portion of said split panel being connected with said front panel and the other portion being connected to said back panel.
 5. The structure as claimed in claim 4 wherein the cell flap is creased and folded so that it is adjacent the cells and disposed normal to the first and second panels.
 6. The structure as claimed in claim 4 including split side panels which have split side flaps and which are hingedly connected to said portions of said split second panel, said split side panels being disposed over the outside of said cushion cells and said side flaps being adhered to said first panel.
 7. The structure as claimed in claim 1 being a flat rectangularly shaped book mailer and wherein said structure includes two arrays of said cushion cells, said panel constituting a first panel which forms the bottom panel of said mailer and being hingedly connected along opposite sides thereof to said arrays of cushion cells, said arrays of cushion cells forming the sides of said mailer, a second panel which forms the top panel of said mailer being aligned with and in parallel relation to said first panel and being hingedly connected to one of said arrays of cushion cells, said cell flap being hingedly connected to the other of said arrays of cushion cells, said flap being parallel to and adjacent said second panel, and a pair of upstanding panels forming the front and back panels of said mailer and being hingedly connected to said first panel.
 8. The structure as claimed in claim 1 wherein said cushion cells are in contact with each other adjacent the bases of said triangularly shaped panels thereof.
 9. The structure as claimed in claim 1 wherein a space is provided between the bases of said triangularly shaped panels of said cushion cells.
 10. The structure as claimed in claim 1 wherein said cushion cells are aligned so as to form said triangularly shaped panels into two rows, the base of each triangularly shaped panel in one row projecting rearwardly with respect to said panels in said one row, said projecting portion of each base having a notch formed therein, said notch interlocking with the base of an adjacent panel in the other row so as to rigidify said cushion cells.
 11. A packaging structure which includes a cushion end cell arrangement and which is formed from a single blank of foldable material by folding said blank about a folding axis, said structure comprising: a web of material having at least two cushion end cells extending from side-to-side across an intermediate portion of said web and being separated by at least one slit in said web, each cushion end cell including at least one pair of inverted generally triangularly shaped panels which are hingedly interconnected along a common leg and which are situated between two free edges in said web, each of said triangularly shaped panels having a second or non-common leg and a base, said base of each panel being defined by a free edge of said web of material, said legs being defined by three creases in said intermediate portion of said web of material, said creases being skew to said folding axis when said web of material is folded to form said cushion end cell, said two non-common legs being parallel to one another before said web of material is folded to form said packaging structure, and the apex of one of said triangularly shaped panels in one pair of said triangularly shaped panels being at one of the free edges defining Said slit and abutting the opposing free edge of said slit which opposing free edge forms the base of another triangularly shaped panel in the adjacent pair of triangularly shaped panels.
 12. The packaging structure as claimed in claim 11 wherein said non-common parallel legs are of unequal length.
 13. The packaging structure as claimed in claim 11 in which at least one of said free edges is segmented into non-collinear edge segments.
 14. The packaging structure as claimed in claim 11 being a book mailer and wherein said web of material includes at least two additional cushion end cells in another portion of said web, a first panel extending between and hingedly interconnected along opposite edges thereof to said cushion end cells and defining the top panel of said mailer, a pair of cell flaps each hingedly interconnected with the outer sides of said cushion end cells, a side panel hingedly interconnected to one side of said first panel, and a second panel interconnected along one side thereof to said side panel and defining the bottom panel of said mailer.
 15. The packaging structure as claimed in claim 14 including a pair of edge panels hingedly interconnected with opposite edges of said second panel, a pair of side flaps hingedly interconnected with said edge panels, a front panel hingedly interconnected to said second panel along the other side thereof, and a front flap hingedly interconnected to said front panel.
 16. The packaging structure as claimed in claim 14 including a front panel hingedly connected to said first panel, said second panel being split with one portion thereof hingedly connected to said front panel and another portion thereof hingedly connected to said side panel.
 17. The packaging structure as claimed in claim 16 including split edge panels and flaps which are hingedly connected to opposite edges of said two portions of said second panel.
 18. A blank of foldable material for forming a packaging structure having a plurality of cushion end cells, said blank including at least two panel portions, and at least one foldable web portion which interconnects said two panel portions, said web portion having a plurality of spaced slits therein extending between said panel portions thereby dividing said web portion into a plurality of web sections and forming a plurality of free edges in said web portion, each of said web sections having three creases therein which extend between two free edges in said web portion and which form a Z in said web section such that two inverted triangularly shaped panels are defined between said creases and said two free edges, each triangularly shaped panel having a base defined by one of said free edges and two legs defined by two of said creases, the crease defining the connecting line of said Z also defining one leg which is common to both of said triangularly shaped panels and which hingedly interconnects said triangularly shaped panels, and the creases defining the end lines of said Z also defining respective non-common legs of said triangularly shaped panels, said non-common legs being parallel to one another, and so that when said web sections are folded along said creases, a cushion end cell is formed in each of said web sections by said triangularly shaped panels therein with each triangularly shaped panel lying a plane which intersects the plane of the other triangularly shaped panel and also the respective planes of said panel portions, and with each web section having a pair of said triangularly shaped panels therein situated between two of said free edges in said web portion such that the apex of one of said triangularly shaped panels in one web section is adjacent the base of another triangularly shaped panel in the adjacent web section.
 19. The blank as claimed in claim 18 in which at least one of said free edges is segmented into non-collinear edge segments.
 20. The blank as claimed in claim 18 wherein said non-common parallel legs are of unequal length.
 21. The bLank as claimed in claim 20 wherein the bases of said triangularly shaped panels in one row of panels project rearwardly with respect to the apexes of said panels, and a slot is provided at said projection and adjacent the apex of the adjacent triangularly shaped panel in said one row of panels, so that, when said blank is folded, each of said slots in one of said bases interlocks with the base of one of said panels in the adjoining row of triangularly shaped panels.
 22. The blank as claimed in claim 18 wherein a line passing through the apexes of said panels in one of said rows of panels is parallel to a line passing through the apexes of said panels in the adjoining row of said panels, each of said lines intersecting the base of each of said panels in the respective row of panels at an angle (alpha) measured within the panel and on the side toward the non-common leg of said panel.
 23. The blank as claimed in claim 22 wherein the angle (alpha) is less than about 90* so that said free edges are separated.
 24. The blank as claimed in claim 22 wherein the angle (alpha) is greater than about 90* so that adjacent cells are in contact.
 25. A packaging structure which includes at least one cushion end cell and which is formed from a single blank of foldable material by folding said blank about a folding axis, said structure comprising: a web of material having said cushion end cell extending from side-to-side across an intermediate portion of said web and between two free edges in said web, said cushion end cell including at least one pair of inverted generally triangularly shaped panels which are hingedly interconnected along a common leg, each of said triangularly shaped panels having a second or non-common leg and a base, said base of each panel being defined by a free edge of said web of material, said legs being defined by three creases in said intermediate portion of said web of material, said creases being skew to said folding axis when said web of material is folded to form said cushion end cell, and said two non-common legs being of unequal length and being parallel to one another before said web of material is folded to form said packaging structure.
 26. The packaging structure as claimed in claim 25 in which at least one of said free edges is segmented into non-collinear edge segments.
 27. A blank of foldable material for forming a packaging structure having at least one cushion end cell, said blank including at least two panel portions, and at least one foldable web portion which interconnects said two panel portions, said web portion have three creases therein which extend between two free edges in said web portion and which form a Z in said web portion such that two inverted triangularly shaped panels are defined between said creases and said two free edges, each triangularly shaped panel having a base defined by one of said free edges and two legs defined by two of said creases, the crease defining the connecting line of said Z also defining one leg which is common to both of said triangularly shaped panels and which hingedly interconnects said triangularly shaped panels, and the creases defining the end lines of said Z also defining respective non-common legs of said triangularly shaped panels, said non-common legs being parallel to one another and being of unequal length, and so that when said web portion is folded along said creases, a cushion end cell is formed in said web portion by said triangularly shaped panels with each triangularly shaped panel lying in a plane which intersects the plane of the other panel and also the respective planes of said panel portions.
 28. The blank as claimed in claim 27 wherein at least one of said free edges is segmented into non-collinear edge segments.
 29. A blank of foldable material for forming a packaging structure having at least two cushion end cells, said blank including at least one foldable web portion which interconnects said two panel portions, said web portiOn having at least one slit therein extending between said panel portions thereby dividing said web portion into at least two web sections and forming a plurality of free edges in said web portion, each of said web sections having three creases therein which extend between two free edges in said web portion and which form a Z in each of said web sections such that two inverted triangularly shaped panels are defined between said creases and said two free edges, each triangularly shaped panel having a base defined by one of said free edges and two legs defined by two of said creases, the crease defining the connecting line of said Z also defining one leg which is common to both of said triangularly shaped panels and which hingedly interconnects said triangularly shaped panels, and the creases defining the end lines of said Z also defining respective non-common legs of said triangularly shaped panels, said non-common legs being parallel to one antoher, and so that when said web sections are folded along said creases, a cushion end cell is formed in each of said web sections by said triangularly shaped panels therein with each triangularly shaped panel lying in a plane which intersects the plane of the other triangularly shaped panel and also the respective planes of said panel portions, and with each web section having a pair of said triangularly shaped panels situated therein between two of said free edges in said web portion such that the apex of one of said triangularly shaped panels in one of said web sections is at one of the free edges defining said slit and abutting the opposing free edge of said slit which opposing free edge forms the base of another triangularly shaped panel in the adjacent web section. 